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Omron CS1D

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Omron CS1D

  1. 1. SYSMAC CS SeriesCS1D-CPU@@H CPU UnitsCS1D-DPL01 Duplex UnitCS1D-PA/PD@@@ Power Supply UnitCS1D Duplex SystemOPERATION MANUAL
  2. 2. CS1D-CPU@@H CPU UnitsCS1D-DPL01 Duplex UnitCS1D-PA/PD@@@ Power Supply UnitCS1D Duplex SystemOperation ManualRevised June 2003
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  4. 4. Notice: OMRON products are manufactured for use according to proper procedures by a qualified operator and only for the purposes described in this manual. The following conventions are used to indicate and classify precautions in this manual. Always heed the information provided with them. Failure to heed precautions can result in injury to people or dam- age to property.!DANGER Indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury.!WARNING Indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.!Caution Indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury, or property damage.OMRON Product References All OMRON products are capitalized in this manual. The word “Unit” is also capitalized when it refers to an OMRON product, regardless of whether or not it appears in the proper name of the product. The abbreviation “Ch,” which appears in some displays and on some OMRON products, often means “word” and is abbreviated “Wd” in documentation in this sense. The abbreviation “PLC” means Programmable Controller. “PC” is used, however, in some Program- ming Device displays to mean Programmable Controller.Visual Aids The following headings appear in the left column of the manual to help you locate different types of information. Note Indicates information of particular interest for efficient and convenient opera- tion of the product. 1,2,3... 1. Indicates lists of one sort or another, such as procedures, checklists, etc. OMRON Electronics LLC 2002-2003 All rights reserved. No part of this publication may be reproduced, stored in a retrieval system, or transmitted, in any form, or by any means, mechanical, electronic, photocopying, recording, or otherwise, without the prior written permission of OMRON. No patent liability is assumed with respect to the use of the information contained herein. Moreover, because OMRON is con- stantly striving to improve its high-quality products, the information contained in this manual is subject to change without notice. Every precaution has been taken in the preparation of this manual. Nevertheless, OMRON assumes no responsibility for errors or omissions. Neither is any liability assumed for damages resulting from the use of the information contained in this publication. v
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  6. 6. TABLE OF CONTENTSPRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xiii 1 Intended Audience . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xiv 2 General Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xiv 3 Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xiv 4 Operating Environment Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xvi 5 Application Precautions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xvii 6 Conformance to EC Directives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xxiiSECTION 1Features and System Configuration . . . . . . . . . . . . . . . . . . . 1 1-1 CS1D Duplex System Overview and Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 1-2 System Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4SECTION 2Specifications, Nomenclature, and Functions . . . . . . . . . . . 11 2-1 Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 2-2 Configuration Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 2-3 Duplex Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 2-4 CPU Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 2-5 File Memory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 2-6 Programming Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54 2-7 Power Supply Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63 2-8 Backplanes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66 2-9 Units on CS1D Long-distance Expansion Racks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68 2-10 Basic I/O Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72 2-11 Unit Current Consumption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78 2-12 CPU Bus Unit Setting Area Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82 2-13 I/O Table Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83SECTION 3Duplex Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85 3-1 Duplex CPU Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86 3-2 Duplex Power Supply Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98SECTION 4Operating Procedures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99 4-1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 4-2 Basic Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102 vii
  7. 7. TABLE OF CONTENTS SECTION 5 Installation and Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113 5-1 Fail-safe Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114 5-2 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115 5-3 Power Supply Wiring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127 5-4 Wiring Methods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129 SECTION 6 PLC Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147 6-1 Overview of PLC Setup. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148 6-2 Specific PLC Setup Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150 SECTION 7 I/O Allocations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169 7-1 I/O Allocations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170 7-2 Data Exchange with CPU Bus Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184 SECTION 8 Memory Areas. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189 8-1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190 8-2 I/O Memory Areas. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191 8-3 I/O Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198 8-4 CS-series DeviceNet Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202 8-5 Data Link Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204 8-6 CPU Bus Unit Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205 8-7 Inner Board Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206 8-8 Special I/O Unit Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208 8-9 Work Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209 8-10 Holding Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209 8-11 Auxiliary Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211 8-12 TR (Temporary Relay) Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 231 8-13 Timer Area. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 232 8-14 Counter Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233 8-15 Data Memory (DM) Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 234 8-16 Extended Data Memory (EM) Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 236 8-17 Index Registers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 237 8-18 Data Registers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 243 8-19 Task Flags . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 244 8-20 Condition Flags . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 245 8-21 Clock Pulses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 248 8-22 Parameter Areas. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 249viii
  8. 8. TABLE OF CONTENTSSECTION 9CPU Unit Operation and the Cycle Time . . . . . . . . . . . . . . . 253 9-1 CPU Unit Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 254 9-2 CPU Unit Operating Modes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 259 9-3 Power OFF Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 261 9-4 Computing the Cycle Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 265 9-5 Instruction Execution Times and Number of Steps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 275SECTION 10Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 297 10-1 Error Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 298 10-2 Error Processing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 299 10-3 Troubleshooting Racks and Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 324SECTION 11Inspection and Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . 327 11-1 Inspections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 328 11-2 Replacing User-serviceable Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 330 11-3 Replacing a CPU Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 333 11-4 Online Replacement of I/O Units, Special I/O Units, and CPU Bus Units . . . . . . . . . . . . . . 336 11-5 Replacing Power Supply Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 348Appendices A Specifications of Basic I/O Units and High-density I/O Units . . . . . . . . . . . . . . . . . . . . . . . 349 B Auxiliary Area Allocations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 389 C Memory Map of PLC Memory Addresses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 427 D PLC Setup Coding Sheets for Programming Console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 429 E Connecting to the RS-232C Port on the CPU Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 439 F Precautions in Replacing CS1-H or CS1 PLCs with CS1D PLCs . . . . . . . . . . . . . . . . . . . . 449 G CJ1W-CIF11 RS-422A Converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 451Index. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 457Revision History . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 465 ix
  9. 9. Certain Terms and Conditions of Sale1. Offer; Acceptance. These terms and conditions (these "Terms") are deemed 12. Warranties. (a) Exclusive Warranty. Sellers exclusive warranty is that the part of all catalogs, manuals or other documents, whether electronic or in writ- Goods will be free from defects in materials and workmanship for a period of ing, relating to the sale of goods or services (collectively, the "Goods") by twelve months from the date of sale by Seller (or such other period expressed Omron Electronics LLC and its subsidiary companies ("Seller"). Seller hereby in writing by Seller). Seller disclaims all other warranties, express or implied. objects to any terms or conditions proposed in Buyers purchase order or other (b) Limitations. SELLER MAKES NO WARRANTY OR REPRESENTATION, documents which are inconsistent with, or in addition to, these Terms. Please EXPRESS OR IMPLIED, ABOUT NON-INFRINGEMENT, MERCHANTABIL- contact your Omron representative to confirm any additional terms for sales ITY OR FITNESS FOR A PARTICULAR PURPOSE OF THE GOODS. from your Omron company. BUYER ACKNOWLEDGES THAT IT ALONE HAS DETERMINED THAT THE2. Prices. All prices stated are current, subject to change without notice by GOODS WILL SUITABLY MEET THE REQUIREMENTS OF THEIR Seller. Buyer agrees to pay the price in effect at time of shipment. INTENDED USE. Seller further disclaims all warranties and responsibility of3. Discounts. Cash discounts, if any, will apply only on the net amount of any type for claims or expenses based on infringement by the Goods or other- invoices sent to Buyer after deducting transportation charges, taxes and wise of any intellectual property right. (c) Buyer Remedy. Sellers sole obliga- duties, and will be allowed only if (i) the invoice is paid according to Sellers tion hereunder shall be to replace (in the form originally shipped with Buyer payment terms and (ii) Buyer has no past due amounts owing to Seller. responsible for labor charges for removal or replacement thereof) the non-4. Orders. Seller will accept no order less than $200 net billing. complying Good or, at Sellers election, to repay or credit Buyer an amount5. Governmental Approvals. Buyer shall be responsible for, and shall bear all equal to the purchase price of the Good; provided that in no event shall Seller costs involved in, obtaining any government approvals required for the impor- be responsible for warranty, repair, indemnity or any other claims or expenses tation or sale of the Goods. regarding the Goods unless Sellers analysis confirms that the Goods were6. Taxes. All taxes, duties and other governmental charges (other than general properly handled, stored, installed and maintained and not subject to contami- real property and income taxes), including any interest or penalties thereon, nation, abuse, misuse or inappropriate modification. Return of any goods by imposed directly or indirectly on Seller or required to be collected directly or Buyer must be approved in writing by Seller before shipment. Seller shall not indirectly by Seller for the manufacture, production, sale, delivery, importation, be liable for the suitability or unsuitability or the results from the use of Goods consumption or use of the Goods sold hereunder (including customs duties in combination with any electrical or electronic components, circuits, system and sales, excise, use, turnover and license taxes) shall be charged to and assemblies or any other materials or substances or environments. Any remitted by Buyer to Seller. advice, recommendations or information given orally or in writing, are not to be7. Financial. If the financial position of Buyer at any time becomes unsatisfactory construed as an amendment or addition to the above warranty. to Seller, Seller reserves the right to stop shipments or require satisfactory 13. Damage Limits; Etc. SELLER SHALL NOT BE LIABLE FOR SPECIAL, INDI- security or payment in advance. If Buyer fails to make payment or otherwise RECT OR CONSEQUENTIAL DAMAGES, LOSS OF PROFITS OR PRODUC- comply with these Terms or any related agreement, Seller may (without liability TION OR COMMERCIAL LOSS IN ANY WAY CONNECTED WITH THE and in addition to other remedies) cancel any unshipped portion of Goods sold GOODS, WHETHER SUCH CLAIM IS BASED IN CONTRACT, WARRANTY, hereunder and stop any Goods in transit until Buyer pays all amounts, includ- NEGLIGENCE OR STRICT LIABILITY. Further, in no event shall liability of ing amounts payable hereunder, whether or not then due, which are owing to it Seller exceed the individual price of the Good on which liability is asserted. by Buyer. Buyer shall in any event remain liable for all unpaid accounts. 14. Indemnities. Buyer shall indemnify and hold harmless Seller, its affiliates and8. Cancellation; Etc. Orders are not subject to rescheduling or cancellation its employees from and against all liabilities, losses, claims, costs and unless Buyer indemnifies Seller fully against all costs or expenses arising in expenses (including attorneys fees and expenses) related to any claim, inves- connection therewith. tigation, litigation or proceeding (whether or not Seller is a party) which arises9. Force Majeure. Seller shall not be liable for any delay or failure in delivery or is alleged to arise from Buyers acts or omissions under these Terms or in resulting from causes beyond its control, including earthquakes, fires, floods, any way with respect to the Goods. Without limiting the foregoing, Buyer (at strikes or other labor disputes, shortage of labor or materials, accidents to its own expense) shall indemnify and hold harmless Seller and defend or settle machinery, acts of sabotage, riots, delay in or lack of transportation or the any action brought against Seller to the extent that it is based on a claim that requirements of any government authority. any Good made to Buyer specifications infringed intellectual property rights of10. Shipping; Delivery. Unless otherwise expressly agreed in writing by Seller: another party. a. Shipments shall be by a carrier selected by Seller; 15. Property; Confidentiality. The intellectual property embodied in the Goods is b. Such carrier shall act as the agent of Buyer and delivery to such carrier the exclusive property of Seller and its affiliates and Buyer shall not attempt to shall constitute delivery to Buyer; duplicate it in any way without the written permission of Seller. Notwithstand- c. All sales and shipments of Goods shall be FOB shipping point (unless oth- ing any charges to Buyer for engineering or tooling, all engineering and tooling erwise stated in writing by Seller), at which point title to and all risk of loss of shall remain the exclusive property of Seller. All information and materials the Goods shall pass from Seller to Buyer, provided that Seller shall retain a supplied by Seller to Buyer relating to the Goods are confidential and propri- security interest in the Goods until the full purchase price is paid by Buyer; etary, and Buyer shall limit distribution thereof to its trusted employees and d. Delivery and shipping dates are estimates only. strictly prevent disclosure to any third party. e. Seller will package Goods as it deems proper for protection against normal 16. Miscellaneous. (a) Waiver. No failure or delay by Seller in exercising any right handling and extra charges apply to special conditions. and no course of dealing between Buyer and Seller shall operate as a waiver11. Claims. Any claim by Buyer against Seller for shortage or damage to the of rights by Seller. (b) Assignment. Buyer may not assign its rights hereunder Goods occurring before delivery to the carrier must be presented in writing to without Sellers written consent. (c) Amendment. These Terms constitute the Seller within 30 days of receipt of shipment and include the original transporta- entire agreement between Buyer and Seller relating to the Goods, and no pro- tion bill signed by the carrier noting that the carrier received the Goods from vision may be changed or waived unless in writing signed by the parties. Seller in the condition claimed. (d) Severability. If any provision hereof is rendered ineffective or invalid, such provision shall not invalidate any other provision. (e) Setoff. Buyer shall have no right to set off any amounts against the amount owing in respect of this invoice. (f) As used herein, "including" means "including without limitation".Certain Precautions on Specifications and Use1. Suitability of Use. Seller shall not be responsible for conformity with any stan- 2. Programmable Products. Seller shall not be responsible for the users pro- dards, codes or regulations which apply to the combination of the Good in the gramming of a programmable Good, or any consequence thereof. Buyers application or use of the Good. At Buyers request, Seller will provide 3. Performance Data. Performance data given in this catalog is provided as a applicable third party certification documents identifying ratings and limitations guide for the user in determining suitability and does not constitute a warranty. of use which apply to the Good. This information by itself is not sufficient for a It may represent the result of Sellers test conditions, and the user must corre- complete determination of the suitability of the Good in combination with the late it to actual application requirements. Actual performance is subject to the end product, machine, system, or other application or use. The following are Sellers Warranty and Limitations of Liability. some examples of applications for which particular attention must be given. 4. Change in Specifications. Product specifications and accessories may be This is not intended to be an exhaustive list of all possible uses of this Good, changed at any time based on improvements and other reasons. It is our prac- nor is it intended to imply that the uses listed may be suitable for this Good: tice to change part numbers when published ratings or features are changed, (i) Outdoor use, uses involving potential chemical contamination or electrical or when significant construction changes are made. However, some specifica- interference, or conditions or uses not described in this document. tions of the Good may be changed without any notice. When in doubt, special (ii) Energy control systems, combustion systems, railroad systems, aviation part numbers may be assigned to fix or establish key specifications for your systems, medical equipment, amusement machines, vehicles, safety application. Please consult with your Sellers representative at any time to con- equipment, and installations subject to separate industry or government firm actual specifications of purchased Good. regulations. 5. Errors and Omissions. The information in this catalog has been carefully (iii) Systems, machines and equipment that could present a risk to life or checked and is believed to be accurate; however, no responsibility is assumed property. Please know and observe all prohibitions of use applicable to for clerical, typographical or proofreading errors, or omissions. this Good. NEVER USE THE PRODUCT FOR AN APPLICATION INVOLVING SERIOUS RISK TO LIFE OR PROPERTY WITHOUT ENSURING THAT THE SYSTEM AS A WHOLE HAS BEEN DESIGNED TO ADDRESS THE RISKS, AND THAT THE SELLERS PRODUCT IS PROPERLY RATED AND INSTALLED FOR THE INTENDED USE WITHIN THE OVERALL EQUIPMENT OR SYSTEM.
  10. 10. About this Manual: This manual describes the installation and operation of the CS1D Duplex Programmable Controllers (PLCs) and includes the sections described below. The CS Series and CJ Series are subdivided as shown in the following table. Unit CS Series CJ Series CPU Units CS1-H CPU Units: CS1H-CPU@@H CJ1-H CPU Units: CJ1H-CPU@@H CS1G-CPU@@H CJ1G-CPU@@H CS1 CPU Units: CS1H-CPU@@-EV1 CJ1 CPU Units: CJ1G-CPU@@-EV1 CS1G-CPU@@-EV1 CS1D CPU Units: CS1D-CPU@@H CJ1M CPU Units: CJ1M-CPU@@ Basic I/O Units CS-series Basic I/O Units CJ-series Basic I/O Units Special I/O Units CS-series Special I/O Units CJ-series Special I/O Units CPU Bus Units CS-series CPU Bus Units CJ-series CPU Bus Units Power Supply Units CS-series Power Supply Units CJ-series Power Supply Units CS1D Power Supply Units Please read this manual and all related manuals listed in the table on the next page and be sure you understand information provided before attempting to install or use CS1D-CPU@@H CPU Units in a PLC System. Section 1 introduces the special features and functions of the CS1D Duplex PLCs and describes the differences between these PLCs and other PLCs. Section 2 provides the specifications, defines the nomenclature, and describes the functions of CS1D PLCs. Section 3 describes the basic operation of a Duplex System. Section 4 outlines the steps required to assemble and operate a CS1D Duplex PLC system. Section 5 describes how to install a PLC System, including mounting the various Units and wiring the System. Be sure to follow the instructions carefully. Improper installation can cause the PLC to mal- function, resulting in very dangerous situations. Section 6 describes the settings in the PLC Setup and how they are used to control CPU Unit opera- tion. Section 7 describes I/O allocations to Basic I/O Units, Special I/O Units, and CPU Bus Units, and data exchange with Units. Section 8 describes the structure and functions of the I/O Memory Areas and Parameter Areas. Section 9 describes the internal operation of the CPU Unit and the cycle used to perform internal pro- cessing. Section 10 provides information on hardware and software errors that occur during PLC operation. Section 11 provides inspection and maintenance information. The Appendices provide Unit specifications, Auxiliary Area words and bits, a memory map of internal addresses, and PLC Setup coding sheets, RS-232C port connection information, and precautions when upgrading a system to duplex operation with CS1D PLCs xi
  11. 11. About this Manual, Continued Name Cat. No. Contents SYSMAC CS Series W405 Provides an outline of and describes the CS1D-CPU@@H CPU Units design, installation, maintenance, and CS1D-DPL01 Duplex Unit other basic operations for a Duplex System CS1D-PA/PD@@@ Power Supply Unit based on CS1D CPU Units. (This manual) Duplex System Operation Manual SYSMAC CS/CJ Series W394 Describes programming and other meth- CS1G/H-CPU@@-EV1, CS1G/H-CPU@@H, CJ1G/H- ods to use the functions of the CS/CJ- CPU@@H, CJ1M-CPU@@, CJ1G-CPU@@, CS1D- series PLCs. CPU@@H Programmable Controllers Programming Manual SYSMAC CS/CJ Series W340 Describes the ladder diagram program- CS1G/H-CPU@@-EV1, CS1G/H-CPU@@H, CJ1G/H- ming instructions supported by CS/CJ- CPU@@H, CJ1M-CPU@@, CJ1G-CPU@@, CS1D- series PLCs. CPU@@H Programmable Controllers Instructions Reference Manual SYSMAC CS/CJ Series W341 Provides information on how to program CQM1H-PRO01-E, C200H-PRO27-E, CQM1-PRO01-E and operate CS/CJ-series PLCs using a Programming Consoles Operation Manual Programming Console. SYSMAC CS/CJ Series W342 Describes the C-series (Host Link) and CS1G/H-CPU@@-EV1, CJ1G-CPU@@, FINS communications commands used CS1W-SCB21-V1/41-V1, CS1W-SCU21, CJ1W-SCU41, with CS/CJ-series PLCs. CS1D-CPU@@H Communications Commands Reference Manual SYSMAC WS02-CXP@@-E W414 Provide information on how to use the CX- CX-Programmer Operation Manual Programmer, a programming device that supports the CS/CJ-series PLCs, and the CX-Net contained within CX-Programmer. SYSMAC WS02-PSTC1-E W344 Describes the use of the CX-Protocol to CX-Protocol Operation Manual create protocol macros as communications sequences to communicate with external devices. !WARNING Failure to read and understand the information provided in this manual may result in per- sonal injury or death, damage to the product, or product failure. Please read each section in its entirety and be sure you understand the information provided in the section and related sections before attempting any of the procedures or operations given.xii
  12. 12. PRECAUTIONSThis section provides general precautions for using the CS1D Programmable Controllers (PLCs) and related devices,including the CS1D-CPU@@H CPU Units, CS1D-DPL01 Duplex Unit, and CS1D-PA/PD@@@ Power Supply Unit.The information contained in this section is important for the safe and reliable application of ProgrammableControllers. You must read this section and understand the information contained before attempting to set up oroperate a PLC system. 1 Intended Audience . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xiv 2 General Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xiv 3 Safety Precautions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xiv 4 Operating Environment Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xvi 5 Application Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xvii 6 Conformance to EC Directives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xxii 6-1 Applicable Directives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xxii 6-2 Concepts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xxii 6-3 Conformance to EC Directives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xxii 6-4 Relay Output Noise Reduction Methods . . . . . . . . . . . . . . . . . . . . . xxiii xiii
  13. 13. Intended Audience 11 Intended Audience This manual is intended for the following personnel, who must also have knowledge of electrical systems (an electrical engineer or the equivalent). • Personnel in charge of installing FA systems. • Personnel in charge of designing FA systems. • Personnel in charge of managing FA systems and facilities.2 General Precautions The user must operate the product according to the performance specifica- tions described in the operation manuals. Please exercise particular care and consult your FA experts before using the product under conditions which are not described in the manual or applying the product to nuclear control systems, railroad systems, aviation systems, vehicles, combustion systems, medical equipment, amusement machines, safety equipment, and other systems, machines, and equipment that may have a serious influence on lives and property if used improperly. Make sure that the ratings and performance characteristics of the product are sufficient for the systems, machines, and equipment, and be sure to provide the systems, machines, and equipment with double safety mechanisms. This manual provides information for programming and operating the Unit. Be sure to read this manual before attempting to use the Unit and keep this man- ual close at hand for reference during operation. !WARNING It is extremely important that a PLC and all PLC Units be used for the speci- fied purpose and under the specified conditions, especially in applications that can directly or indirectly affect human life.3 Safety Precautions !WARNING The CPU Unit refreshes I/O even when the program is stopped (i.e., even in PROGRAM mode). Confirm safety thoroughly in advance before changing the status of any part of memory allocated to I/O Units, Special I/O Units, or CPU Bus Units. Any changes to the data allocated to any Unit may result in unex- pected operation of the loads connected to the Unit. Any of the following oper- ation may result in changes to memory status. • Transferring I/O memory data to the CPU Unit from a Programming Device. • Changing present values in memory from a Programming Device. • Force-setting/-resetting bits from a Programming Device. • Transferring I/O memory files from a Memory Card or EM file memory to the CPU Unit. • Transferring I/O memory from a host computer or from another PLC on a network. !WARNING Do not attempt to take any Unit apart while the power is being supplied. Doing so may result in electric shock.xiv
  14. 14. Safety Precautions 3 !WARNING Do not touch any of the terminals or terminal blocks while the power is being supplied. Doing so may result in electric shock. !WARNING Do not attempt to disassemble, repair, or modify any Units. Any attempt to do so may result in malfunction, fire, or electric shock. !WARNING Do not touch the Power Supply Unit while power is being supplied or immedi- ately after power has been turned OFF. Doing so may result in electric shock. !WARNING Provide safety measures in external circuits (i.e., not in the Programmable Controller), including the following items, to ensure safety in the system if an abnormality occurs due to malfunction of the PLC or another external factor affecting the PLC operation. Not doing so may result in serious accidents. With a CS1D System operating in Duplex Mode, operation will be stopped and all outputs will be turned OFF in the following circumstances. • When self-diagnosis simultaneously detects an error in both the active and standby CPU Units. • When a severe failure alarm (FALS) instruction is simultaneously exe- cuted in both the active and standby CPU Units. • When self-diagnosis detects an error in Simplex Mode or when it detects an error during duplex initialization for Duplex Mode. • When a severe failure alarm (FALS) instruction is executed in Simplex Mode or during duplex initialization for Duplex Mode. As a countermeasure for the above errors, external safety measures must be provided to ensure safety in the system. !WARNING The PLC outputs may remain ON or OFF due to deposition or burning of the output relays or destruction of the output transistors. As a countermeasure for such problems, external safety measures must be provided to ensure safety in the system. !WARNING When the 24-V DC output (service power supply to the PLC) is overloaded or short-circuited, the voltage may drop and result in the outputs being turned OFF. As a countermeasure for such problems, external safety measures must be provided to ensure safety in the system. !Caution Confirm safety before transferring data files stored in the file memory (Mem- ory Card or EM file memory) to the I/O area (CIO) of the CPU Unit using a peripheral tool. Otherwise, the devices connected to the output unit may mal- function regardless of the operation mode of the CPU Unit. !Caution Fail-safe measures must be taken by the customer to ensure safety in the event of incorrect, missing, or abnormal signals caused by broken signal lines, momentary power interruptions, or other causes. Serious accidents may result from abnormal operation if proper measures are not provided. !Caution Execute online edit only after confirming that no adverse effects will be caused by extending the cycle time. Otherwise, the input signals may not be readable. xv
  15. 15. Operating Environment Precautions 4 !Caution The CS1D CPU Units automatically back up the user program and parameter data to flash memory when these are written to the CPU Unit. I/O memory (including the DM, EM, and HR Areas), however, is not written to flash mem- ory. The DM, EM, and HR Areas can be held during power interruptions with a battery. If there is a battery error, the contents of these areas may not be accurate after a power interruption. If the contents of the DM, EM, and HR Areas are used to control external outputs, prevent inappropriate outputs from being made whenever the Battery Error Flag (A40204) is ON. !Caution Confirm safety at the destination node before transferring a program to another node or changing contents of the I/O memory area. Doing either of these without confirming safety may result in injury. !Caution Tighten the screws on the terminal block of the AC Power Supply Unit to the torque specified in the operation manual. The loose screws may result in burning or malfunction.4 Operating Environment Precautions !Caution Do not operate the control system in the following locations: • Locations subject to direct sunlight. • Locations subject to temperatures or humidity outside the range specified in the specifications. • Locations subject to condensation as the result of severe changes in tem- perature. • Locations subject to corrosive or flammable gases. • Locations subject to dust (especially iron dust) or salts. • Locations subject to exposure to water, oil, or chemicals. • Locations subject to shock or vibration. !Caution Take appropriate and sufficient countermeasures when installing systems in the following locations: • Locations subject to static electricity or other forms of noise. • Locations subject to strong electromagnetic fields. • Locations subject to possible exposure to radioactivity. • Locations close to power supplies. !Caution The operating environment of the PLC System can have a large effect on the longevity and reliability of the system. Improper operating environments can lead to malfunction, failure, and other unforeseeable problems with the PLC System. Be sure that the operating environment is within the specified condi- tions at installation and remains within the specified conditions during the life of the system.xvi
  16. 16. Application Precautions 55 Application Precautions Observe the following precautions when using the PLC System. • Do not use the C200H/CS-series Power Supply Units (C200H-P@@@@) in a CS1D PLC. System operation will not be dependable and may stop. • Do not use a CS1D Power Supply Unit (CS1D-PA/PD@@@) for any PLC other than a CS1D PLC. Operational errors and burning will result. • If duplex Power Supply Units are to be used, calculate the current con- sumption so that the system will be able to operate with a single Power Supply Unit in case an error occurs in the other Power Supply Unit. If two different kinds of Power Supply Units are to be used, calculate the current consumption using the output of the smaller-capacity Power Supply Unit. • Do not mount a CS1D CPU Unit to any Backplane other than a CS1D- BC052 Duplex CPU Backplane. Operational errors will result. • Do not mount a CS1 or CS1-H CPU Unit to a CS1D-BC052 Duplex CPU Backplane. Operational errors will result. • The cycle time will be increased over the normal cycle time whenever duplex operation is initialized, including when power is turned ON, when the initialization button is pressed, when operation is started, and when data is transferred. The increase will be a maximum of 190 ms for the CS1D-CPU65H and 520 ms for the CS1D-CPU67H. Set the monitoring time (10 to 40,000 ms, default: 1 s) for the cycle time high enough to allow for this increase. Also, confirm that the system will operate correctly and safely even for the maximum cycle time, including the increase for duplex initialization. • If operation switches from Duplex Mode to Simplex Mode, processing to synchronize the active and standby CPU Units will no longer be per- formed, resulting in a shorter cycle time. The more instructions requiring synchronization (such as IORF, DLNK, IORD, IOWR, PID, RXD, FREAD, and FWRIT) are used, the greater the difference between Duplex Mode and Simplex Mode operation will be (with Duplex Mode having the longer cycle time). Confirm that the system will operate correctly and safely even for the cycle time in both Simplex and Duplex Modes. • If the active CPU Unit is switched when PTs or host computers are con- nected to the RS-232C port on both the active and standby CPU Units, communications may be interrupted momentarily. Always enable retry process in communications programs at the PTs or host computers. • Before replacing a Unit online, always disable the operation of all con- nected external devices before starting the replacement procedure. Unex- pected outputs from the Unit being replaced may result in unexpected operation of controlled devices or systems. • Always following the procedures provided in the operation manual when performing online replacement. • When replacing a Unit online, always replace it with a Unit that has the same specifications. • Never connect pin 6 (5-V power supply) on the RS-232C port on the CPU Unit to any device other than an NT-AL001-E or CJ1W-CIF11 Adapter. The external device or the CPU Unit may be damaged. • You must use the CX-Programmer (programming software that runs on Windows) if you need to program more than one task. A Programming Console can be used to program only one cyclic task. A Programming xvii
  17. 17. Application Precautions 5 Console can, however, be used to edit multitask programs originally cre- ated with the CX-Programmer. !WARNING Always heed these precautions. Failure to abide by the following precautions could lead to serious or possibly fatal injury. • Always connect to a ground of 100 Ω or less when installing the Units. Not connecting to a ground of 100 Ω or less may result in electric shock. • A ground of 100 Ω or less must be installed when shorting the GR and LG terminals on the Power Supply Unit. • Always turn OFF the power supply to the PLC before attempting any of the following. Not turning OFF the power supply may result in malfunction or electric shock. • Mounting or dismounting Power Supply Units, I/O Units, CPU Units, In- ner Boards, or any other Units. • Assembling the Units. • Setting DIP switches or rotary switches. • Connecting cables or wiring the system. • Connecting or disconnecting the connectors. !Caution Failure to abide by the following precautions could lead to faulty operation of the PLC or the system, or could damage the PLC or PLC Units. Always heed these precautions. • The user program and parameter area data in the CPU Units are backed up in the built-in flash memory. The BKUP indicator will light on the front of the CPU Unit when the backup operation is in progress. Do not turn OFF the power supply to the CPU Unit when the BKUP indicator is lit. The data will not be backed up if power is turned OFF. • The PLC Setup is set to specify using the mode set on the Programming Console and a Programming Console is not connected, the CPU Unit will start in RUN mode. This is the default setting in the PLC Setup. (A CS1 CPU Unit will start in PROGRAM mode under the same conditions.) • When creating an AUTOEXEC.IOM file from a Programming Device (a Programming Console or the CX-Programmer) to automatically transfer data at startup, set the first write address to D20000 and be sure that the size of data written does not exceed the size of the DM Area. When the data file is read from the Memory Card at startup, data will be written in the CPU Unit starting at D20000 even if another address was set when the AUTOEXEC.IOM file was created. Also, if the DM Area is exceeded (which is possible when the CX-Programmer is used), the remaining data will be written to the EM Area. Refer to information on file operations in the CS/CJ Series Programming Manual for details. • Always turn ON power to the PLC before turning ON power to the control system. If the PLC power supply is turned ON after the control power sup- ply, temporary errors may result in control system signals because the output terminals on DC Output Units and other Units will momentarily turn ON when power is turned ON to the PLC. • Fail-safe measures must be taken by the customer to ensure safety in the event that outputs from Output Units remain ON as a result of internal cir- cuit failures, which can occur in relays, transistors, and other elements.xviii
  18. 18. Application Precautions 5 • Fail-safe measures must be taken by the customer to ensure safety in the event of incorrect, missing, or abnormal signals caused by broken signal lines, momentary power interruptions, or other causes. • Interlock circuits, limit circuits, and similar safety measures in external cir- cuits (i.e., not in the Programmable Controller) must be provided by the customer. • Do not turn OFF the power supply to the PLC when data is being trans- ferred. In particular, do not turn OFF the power supply when reading or writing a Memory Card. Also, do not remove the Memory Card when the BUSY indicator is lit. To remove a Memory Card, first press the memory card power supply switch and then wait for the BUSY indicator to go out before removing the Memory Card. • If the I/O Hold Bit is turned ON, the outputs from the PLC will not be turned OFF and will maintain their previous status when the PLC is switched from RUN or MONITOR mode to PROGRAM mode. Make sure that the external loads will not produce dangerous conditions when this occurs. (When operation stops for a fatal error, including those produced with the FALS(007) instruction, all outputs from Output Unit will be turned OFF and only the internal output status will be maintained.) • The contents of the DM, EM, and HR Areas in the CPU Unit are backed up by a Battery. If the Battery voltage drops, this data may be lost. Provide countermeasures in the program using the Battery Error Flag (A40204) to re-initialize data or take other actions if the Battery voltage drops. • When supplying power at 200 to 240 V AC, always remove the metal jumper from the voltage selector terminals on the Power Supply Unit (except for Power Supply Units with wide-range specifications). The prod- uct will be destroyed and must be replaced if 200 to 240 V AC is supplied while the metal jumper is attached. Refer to 5-4 Wiring Methods for details. • Always use the power supply voltages specified in the operation manuals. An incorrect voltage may result in malfunction or burning. • Take appropriate measures to ensure that the specified power with the rated voltage and frequency is supplied. Be particularly careful in places where the power supply is unstable. An incorrect power supply may result in malfunction. • Install external breakers and take other safety measures against short-cir- cuiting in external wiring. Insufficient safety measures against short-cir- cuiting may result in burning. • Do not apply voltages to the Input Units in excess of the rated input volt- age. Excess voltages may result in burning. • Do not apply voltages or connect loads to the Output Units in excess of the maximum switching capacity. Excess voltage or loads may result in burning. • Disconnect the functional ground terminal when performing withstand voltage tests. Not disconnecting the functional ground terminal may result in burning. • Install the Units properly as specified in the operation manuals. Improper installation of the Units may result in malfunction. • Be sure that all the Backplane mounting screws, terminal block screws, and cable connector screws are tightened to the torque specified in the relevant manuals. Incorrect tightening torque may result in malfunction. xix
  19. 19. Application Precautions 5 • Leave the label attached to the Unit when wiring. Removing the label may result in malfunction if foreign matter enters the Unit. • Remove the label after the completion of wiring to ensure proper heat dis- sipation. Leaving the label attached may result in malfunction. • Use crimp terminals for wiring. Do not connect bare stranded wires directly to terminals. Connection of bare stranded wires may result in burning. • Wire all connections correctly. • Double-check all wiring and switch settings before turning ON the power supply. Incorrect wiring may result in burning. • Mount Units only after checking terminal blocks and connectors com- pletely. • Be sure that the terminal blocks, Memory Units, expansion cables, and other items with locking devices are properly locked into place. Improper locking may result in malfunction. • Check switch settings, the contents of the DM Area, and other prepara- tions before starting operation. Starting operation without the proper set- tings or data may result in an unexpected operation. • Check the user program for proper execution before actually running it on the Unit. Not checking the program may result in unexpected operation. • Confirm that no adverse effect will occur in the system before attempting any of the following. Not doing so may result in an unexpected operation. • Changing the operating mode of the PLC. • Force-setting/force-resetting any bit in memory. • Changing the present value of any word or any set value in memory. • Resume operation only after transferring to the new CPU Unit the con- tents of the DM Area, HR Area, and other data required for resuming operation. Not doing so may result in an unexpected operation. • Do not pull on the cables or bend the cables beyond their natural limit. Doing either of these may break the cables. • Do not place objects on top of the cables or other wiring lines. Doing so may break the cables. • Do not use commercially available RS-232C personal computer cables. Always use the special cables listed in this manual or make cables according to manual specifications. Using commercially available cables may damage the external devices or CPU Unit. • When replacing parts, be sure to confirm that the rating of a new part is correct. Not doing so may result in malfunction or burning. • Before touching a Unit, be sure to first touch a grounded metallic object in order to discharge any static build-up. Not doing so may result in malfunc- tion or damage. • When transporting or storing circuit boards, cover them in antistatic mate- rial to protect them from static electricity and maintain the proper storage temperature. • Do not touch circuit boards or the components mounted to them with your bare hands. There are sharp leads and other parts on the boards that may cause injury if handled improperly. • Do not short the battery terminals or charge, disassemble, heat, or incin- erate the battery. Do not subject the battery to strong shocks. Doing any of these may result in leakage, rupture, heat generation, or ignition of the battery. Dispose of any battery that has been dropped on the floor or oth-xx
  20. 20. Application Precautions 5 erwise subjected to excessive shock. Batteries that have been subjected to shock may leak if they are used. • UL standards required that batteries be replaced only by experienced technicians. Do not allow unqualified persons to replace batteries. xxi
  21. 21. Conformance to EC Directives 66 Conformance to EC Directives6-1 Applicable Directives • EMC Directives • Low Voltage Directive6-2 Concepts EMC Directives OMRON devices that comply with EC Directives also conform to the related EMC standards so that they can be more easily built into other devices or the overall machine. The actual products have been checked for conformity to EMC standards (see the following note). Whether the products conform to the standards in the system used by the customer, however, must be checked by the customer. EMC-related performance of the OMRON devices that comply with EC Direc- tives will vary depending on the configuration, wiring, and other conditions of the equipment or control panel on which the OMRON devices are installed. The customer must, therefore, perform the final check to confirm that devices and the overall machine conform to EMC standards. Note Applicable EMC (Electromagnetic Compatibility) standards are as follows: EMS (Electromagnetic Susceptibility): EN61131-2 or EN61000-6-2 EMI (Electromagnetic Interference): EN50081-2 or EN61000-6-4 (Radiated emission: 10-m regulations) Low Voltage Directive Always ensure that devices operating at voltages of 50 to 1,000 V AC and 75 to 1,500 V DC meet the required safety standards for the PLC (EN61131-2).6-3 Conformance to EC Directives The CS1D Duplex PLCs comply with EC Directives. To ensure that the machine or device in which the CS1D Duplex PLC is used complies with EC Directives, the PLC must be installed as follows: 1,2,3... 1. The CS1D Duplex PLC must be installed within a control panel. 2. You must use reinforced insulation or double insulation for the DC power supplies used for the communications power supply and I/O power sup- plies. 3. CS1D Duplex PLCs complying with EC Directives also conform to the Common Emission Standard (EN50081-2). Radiated emission character- istics (10-m regulations) may vary depending on the configuration of the control panel used, other devices connected to the control panel, wiring, and other conditions. You must therefore confirm that the overall machine or equipment complies with EC Directives.xxii
  22. 22. Conformance to EC Directives 66-4 Relay Output Noise Reduction Methods The CS1D Duplex PLCs conforms to the Common Emission Standards (EN50081-2) of the EMC Directives. However, noise generated by relay out- put switching may not satisfy these Standards. In such a case, a noise filter must be connected to the load side or other appropriate countermeasures must be provided external to the PLC. Countermeasures taken to satisfy the standards vary depending on the devices on the load side, wiring, configuration of machines, etc. Following are examples of countermeasures for reducing the generated noise.Countermeasures (Refer to EN50081-2 for more details.) Countermeasures are not required if the frequency of load switching for the whole system with the PLC included is less than 5 times per minute. Countermeasures are required if the frequency of load switching for the whole system with the PLC included is more than 5 times per minute.Countermeasure Examples When switching an inductive load, connect an surge protector, diodes, etc., in parallel with the load or contact as shown below. Circuit Current Characteristic Required element AC DCCR method Yes Yes If the load is a relay or solenoid, there is The capacitance of the capacitor must a time lag between the moment the cir- be 1 to 0.5 µF per contact current of cuit is opened and the moment the load 1 A and resistance of the resistor must is reset. be 0.5 to 1 Ω per contact voltage of 1 V. Inductive If the supply voltage is 24 or 48 V, insert These values, however, vary with the load the surge protector in parallel with the load and the characteristics of the Power supply load. If the supply voltage is 100 to relay. Decide these values from experi- 200 V, insert the surge protector ments, and take into consideration that between the contacts. the capacitance suppresses spark dis- charge when the contacts are sepa- rated and the resistance limits the current that flows into the load when the circuit is closed again. The dielectric strength of the capacitor must be 200 to 300 V. If the circuit is an AC circuit, use a capacitor with no polarity. xxiii
  23. 23. Conformance to EC Directives 6 Circuit Current Characteristic Required element AC DC No Yes The diode connected in parallel with The reversed dielectric strength valueDiode method the load changes energy accumulated of the diode must be at least 10 times by the coil into a current, which then as large as the circuit voltage value. Inductive flows into the coil so that the current will The forward current of the diode must be converted into Joule heat by the be the same as or larger than the load Power load resistance of the inductive load. current. supply This time lag, between the moment the The reversed dielectric strength value circuit is opened and the moment the of the diode may be two to three times load is reset, caused by this method is larger than the supply voltage if the longer than that caused by the CR surge protector is applied to electronic method. circuits with low circuit voltages. Varistor method Yes Yes The varistor method prevents the impo- --- sition of high voltage between the con- tacts by using the constant voltage characteristic of the varistor. There is Inductive time lag between the moment the cir- load Power cuit is opened and the moment the load supply is reset. If the supply voltage is 24 or 48 V, insert the varistor in parallel with the load. If the supply voltage is 100 to 200 V, insert the varistor between the con- tacts. When switching a load with a high inrush current such as an incandescent lamp, suppress the inrush current as shown below. Countermeasure 1 Countermeasure 2 R OUT OUT R COM COM Providing a dark current of Providing a limiting resistor approx. one-third of the rated value through an incandescent lampxxiv
  24. 24. SECTION 1 Features and System ConfigurationThis section introduces the features and system configuration of a CS1D Duplex PLC System. 1-1 CS1D Duplex System Overview and Features . . . . . . . . . . . . . . . . . . . . . . . . 2 1-1-1 CS1D Duplex System Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 1-1-2 CS1D System Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 1-2 System Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 1-2-1 CS1D Duplex Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 1-2-2 CS1D Simplex Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 1
  25. 25. CS1D Duplex System Overview and Features Section 1-11-1 CS1D Duplex System Overview and Features1-1-1 CS1D Duplex System Overview The CS1D Duplex System is a highly reliable Programmable Controller (PLC) System. By providing duplex CPU Units (with Duplex Inner Boards), Power Supply Units, and Communications Units, the CS1D can continue control operations and be restored with no need to shut down the entire system in the event of an error or malfunction. Even if an error occurs in the active CPU Unit, the standby CPU Unit contin- ues operation, thus preventing a system shutdown. In the same way, with its duplex Power Supply Units and Communications Units, the CS1D provides high reliability in the event of an error in the power supply system or the active Communications Unit. Moreover, the CS1D provides various maintenance functions, such as online Unit replacement and automatic recovery to duplex operation, that enable continuous control operations and quick recovery without shutting down the entire system if an error occurs. Duplex Unit Communications Units (Controller Link Units) CS1D CPU Units CS1D Power Supply Units DPL01 RUN DPL STATUS RUN ERR/ALM ACTIVE ERR/ALM L CPU STATUS INH BKUP ACTIVE INH BKUP R CPU STATUS PRPHL COMM PRPHL COMM SYSMAC LEFT CPU SYSMAC CS1D-CPU67H USE CS1D-CPU67H PROGRAMMABLE CONTROLLER PROGRAMMABLE CONTROLLER NO USE RIGHT CPU USE MCPWR BUSY MCPWR BUSY NO USE OPEN OPEN DPL SW ON OFF SPL DPL ACT. ACT. LEFT RIGHT ON PERIPHERAL PERIPHERAL INIT. SW PRPHL COMM A39512 RSV PORT ON PORT DUPLEX Duplex Duplex Duplex Power Communications CPU Units Supply Units Units Note Use CS1D CPU Units of production lot No. 030422 (April 22, 2003, produc- tion) onwards when Duplex Inner Boards are included.1-1-2 CS1D System FeaturesDuplex CPU Units (with Duplex Inner Boards) Two CPU Units and one Duplex Unit are mounted. The two CPU Units always run the same users program. One of them exe- cutes the system I/O while the other remains on standby. If an error (see note) occurs in the controlling CPU Unit (called the active CPU Unit), control is switched to the other CPU Unit (called the standby CPU Unit), and operation continues. (The system will stop, however, if the same error occurs in the standby CPU Unit, or if another operation switching error or a fatal error occurs.) Note Operation will be taken over by the standby CPU Unit if any of the following operation switching errors: CPU error, memory error, cycle time overrun error, program error, FALS error, fatal Inner Board error. A fatal Inner Board error is an operation switching error, so Duplex Inner Boards can also be mounted. Mounting Duplex Inner Boards (e.g., Loop Con- trol Boards) in both CPU Units allows operation to be switched to the standby Inner Board when a fatal Inner Board error occurs in the active Inner Board.2
  26. 26. CS1D Duplex System Overview and Features Section 1-1Using the Hot Standby Method With the hot standby method, the standby CPU Unit operates with the same status as the active CPU Unit. Using this method provides the following bene- fits. 1,2,3... 1. There is no need to incorporate special programming for duplex opera- tions, such as programming to switch when an error occurs, and thus there is no need for the duplex setup to be considered in individual parameter settings. 2. The time required for switching when an error occurs is shortened, en- abling operation to be continued without any interruption. Standby CPU Unit: Remains on standby while Active CPU Unit: executing the program. Controls operation. No special programming is required, because D C duplex CPU Units are C operating. P P P U L UAutomatic Recovery to Duplex Mode With existing duplex systems (such as the CVM1D), it is necessary to manu- ally return the system to Duplex Mode after a CPU Unit error occurs during operation in Duplex Mode and operation is switched to Simplex Mode. With the CS1D Duplex System, operation is automatically returned to the orig- inal Duplex Mode when the error that caused the switch to Simplex Mode is cleared. Unmanned duplex operation can be continued even when incidental errors occur temporarily due to causes such as noise.Duplex Power Supply Units Even if one of the Power Supply Units breaks down, the other one continues providing power automatically. The Power Supply Unit where the error occurred can be replaced online after first turning OFF the primary-side power supply. The Power Supply Unit error can also be checked by means of flags in the AR Area.Duplex Communications (Controller Link) Units Two Communications Units (see note) are connected by fiber-optic cable. If one of the Units stops communicating, the other one continues communica- tions. Note The following Communications Units support duplex operation: CS1W- CLK12-V1 Controller Link Units (H-PCF Cable) and CS1W-CLK52-V1 (GI Cable). As shown in the following diagram, two Controller Link Units are mounted in a single network with identical unit numbers and node addresses. One of the Controller Link Units is in standby mode. When an error is detected at the active Controller Link Unit, the standby Con- troller Link Unit switches to active operating status. This allows communica- tions to continue without the node being disconnected. 3
  27. 27. System Configuration Section 1-2 Identical unit numbers and node addresses Identical unit numbers and node addresses C C C D C P P C C C D C P P L L P P P S S L L P P P S S K K U L U U U K K U L U U U System with duplex communications. System with duplex communications. Fiber-optic cable (ring connection) C C C P P C C P CLK: Controller Link Unit L L P S S L P S K K U U U K U U CPU: CPU Unit DPL: Duplex Unit System with duplex communications. System without duplex communications PSU: Power Supply Unit Identical unit numbers and node addressesCS Series Compatibility The CS1D CPU Units (CS1D-CPU67H and CS1D-CPU65H) can use the same programs and Units as the CS1 and CS1-H CPU Units.Online Replacement of CPU Units CPU Units can be replaced online without stopping system operation.Online Replacement of Basic I/O Units, Special I/O Units, and CPU Bus Units Basic I/O Units, Special I/O Units, and CPU Bus Units can be replaced online by means of Programming Console operations. In particular, with Duplex Communications Units (e.g., Controller Link Units, optical link type, token ring mode), Communications Units can be replaced without disconnecting the node or interrupting communications.1-2 System Configuration A CS1D System can be configured as either a CS1D Duplex System or a CS1D Simplex System.1-2-1 CS1D Duplex Systems A CS1D System with two CPU Units mounted is called a CS1D Duplex Sys- tem.Duplex Functions The following duplex functions are supported by a CS1D Duplex System. Duplex function Support Duplex CPU Units (with Duplex Inner Boards) Yes Duplex Power Supply Units Yes Duplex Communications Units (e.g., Controller Link Units) Yes Online Unit replacement YesThe Two Modes in a CS1D Duplex System A CS1D Duplex System can be operated in either Duplex Mode or Simplex Mode. • Duplex Mode In Duplex Mode, the CPU Units are placed in duplex system status. If a fatal error occurs in the active CPU Unit, control is switched to the standby CPU Unit and operation continues.4

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